My color wire diagram isn't completely correct but using that and the b/w diagram from the manual, I finally figured it out.

When I initially started checking into the harness, I found bare and broken wires, connections to nothing, wires spliced and very lazy tape jobs. I finally had to unwrap the whole harness and separate all the runs. Now, I need to find some dry vinyl tape and re-wrap the harness. I borrowed a label maker and every connection is going to get a letter code so this mess never happens again.

6.26.2010

The project bike is alive! The air box needs new rubber tubes for the carbs, they're out of shape and rock hard in areas. The engine ran great, no crazy noises and no oil leaks. Now we need to finish the air box, dial in the mixture, new chain, new front caliper and she'll be good to go.

Got the valves pulled on my 750. Used my handy new Craftsman valve tool, worked great! Tomorrow will be the rematch, me VS the wiring.

I'm enjoying a gluten-free beer as I make this post. Tasty, wish it was ice cold.

6.20.2010

We picked up Funky's frame from the welding shop Sat morning. The splice kit turned out amazing, probably the cleanest weld job I have ever seen. After some running around for misc supplies and tools, we finally got down to business. Funky began painting his frame, while I put the gauge cluster and controls back on my bike.

As I began to route the wiring harness, I found a few issues that I had overlooked. So, I pulled the loom wrap off and found two broken wires and lots of spots with grey electrical tape. I pulled the tape and found very factory looking solder joints. I re-wrapped the harness and pulled the wires that dead end. It took some test fitting to find the best route for the harness but we finally got it squared away. I still hold my grudge with Honda over stuffing all the wiring in the headlight bucket from when I did my CL450. The CB750 is the exact same, so I'll save the fun of connect the colors for another day. I installed my new heavy duty fuse block in the tool tray, so it's a bit more accessible.

Another friend with a 77 CB750 showed up and we checked out some carb issues he's been having. The emulsion tube on carb 1 is stripped out but a quick cleaning made some improvement. We tinkered with the black 77 project bike and got it to turn over but the carbs are too gummed up to flow good gas. So, it goes back to the bottom of the list. At least we got all the bad gas out of the tank.

Once Funky's frame was dry, we began reassembly. Installed the swing arm with bronze bushings and the new tapered stem bearings. There is still a bit of wiring to finish on his bike, so we got it to a rolling frame and called it a night.

Counting all the running around, we put in a roughly 16 hour day in the shop. A great way to spend a Saturday.

6.16.2010

Some nights in the shop don't go well, no matter how hard you try. We had a hell of a time getting the swing arm back on. After fighting it for about 45 minutes, we finally won. Then the rear wheel was causing us some grief, my temper started to rise so we switched to the front wheel. Going back to the rear wheel after a break didn't make a damn difference. I give up for tonight.

*update*I let hunger and frustration get the best of me. I looked at the rear wheel assembly again. Like a moron, I forgot the freaking chain adjusters!!! Hmmm.. maybe that's were the gap came from.

6.15.2010

Went on an adventure last night, through crazy wind, lightening and sheets of rain. Picked up a 33 year old bike that looks like it's been garage kept it's whole life.

Pics later today if the sun decides to come out.

**edit**

Here you go:

1977 CB750K

Needs new tires, oil change, flush and clean the whole fuel system and a chain. We're going to get it back to stock and then it will go up for sale. The 4 into 1 will get removed and we'll put the beautiful stock pipes back on.

6.13.2010

In response to Gymi's comment about my progess, I thought I'd give a little info on why things are really rocking in the shop with the two CB750s.

I really want to get some riding in this summer on my own bike. My last two projects were sold before I ever had them plated or really got to ride them. I sold my CL450 to pay for wedding rings and sold the CB350 because I was tired of fighting it. I used to be much much worse working in the garage. I would jump from job to job and never really get anything finished. I just didn't have the concentration to get things done.

Turns out, I was battling some health issues that were making a fair amount of my life very very shitty. My thyroid crapped out and now it's getting under control. Found out I have a gluten allergy and drastically changed my diet. Plus, I decided to get into better shape. It's all got me closer to where I used to be in my life. So now, I can actually get things done in the shop. I might also finally take the online motorcycle mechanics course again and finish it! I gave up about halfway through and only absorbed about a third of what I studied. Once again, thanks to my thyroid issues.

So, there you go. The toughest part of all this work on my bike is finding the cash for parts. But isn't that how it always is?

Pulled the pistons and put them threw the parts washer. There is some slight pitting but nothing major (I think). We did a quick test on the valves by spraying carb cleaner into the exhaust/intake. The exhaust side had a few leaks. So, we'll be picking up a valve spring tool and pulling them. We have a set of new guides but the valves might be kaput. Anywho, pics from tonight.

The rings weren't too bad either but no better time to replace them than now.

6.11.2010

Got the engine last night and after a quick degreasing, decided to tear into it. So far, we haven't found anything terrible. The pistons have a good amount of carbon on them and none of the valves look burnt or cracked. The rings are in good shape too. Everything will get cleaned up, checked and reinstalled. Tomorrow we'll be cracking the crankcase and digging around in there. The cases need to be media blasted (probably use walnut) to get the terrible paint job off. Whoever painted the engine didn't use hi-temp paint, so it's crinkled and flaking off. Thankfully, they didn't prep the surface, so the aluminum is still in good shape. On with the pics.

6.09.2010

I installed the tapered stem bearings last night with the 4mm spacer that is included in the kit (Parts+Plus SSH750). This left me with only a few threads on the stem for the stem nut. Plus, it rippled the lower seal and was causing drag with the bearings.

Today, I reassembled the stock lower bearings and compared them to the tapered set. There was about a 0.75mm difference w/o the spacer. So, I reinstalled them in this order: thin stock washer, rubber seal and bearing cage. This gave me enough thread on the stem to properly seat the stem nut.

I used a "long fiber" grease from Valvoline, Cerulean Heavy Duty. Requesting "long fiber" bearing grease stumped the guys at AutoZone and NAPA. A little googling turned up a comparison of grease. There are two basic types of grease. One is "long fiber", if you stretch it out between your fingers, it has long threads. This is used for low speed applications like stem bearings and swing arm bushings. The other has the consistency of butter. Yum!

After inserting the stem and adjusting the stem nut, the steering is nice and smooth. The front end has been reinstalled. I decided to stick with the rusty headlight ears for now. Next year, I'll go with the lowering kit and replace the fork tubes and use universal ears.

Success! Tomorrow we're picking up the engine. I plan on pulling the top end and seeing just what is going on in cylinder #4. Hopefully, it's just a stuck ring. While we're in there, I'll measure the cylinders and see if it really does have an 836cc kit installed.

6.04.2010

Success! They both went in without trouble. One side slid in with minimal tapping but thankfully it's not loose within the swing arm. Tomorrow I'll be looking for the missing piece of the puzzle, the elusive swing arm collar.

The collar races are in the freezer and might get installed tomorrow. If I find the collar, I might very well be able to get the bike back to a rolling frame this weekend.

6.03.2010

My fork tubes are pitted and nasty but thankfully it's not in the travel area. So, it doesn't cause any issues with the fork seals. The stock headlight ears are in rough shape, so I'm thinking about using a universal style. If I go that route, the nasty tubes will show. Part of me doesn't care and just wants to get it on the road on the cheap. If I go the universal route, I'll have to return the fork boots I just received and try to track down dust caps or boots that don't need the stock ears.

Going on the cheap, I could re-use the ears and the boots I currently have. This would look rougher than I'd like but I could save my pennies and put them towards the lowering kit from Cycle Exchange and drop the height by about an inch. This would also give me shiny new fork tubes. While the front end is off again, I could rebuild the forks since it will probably be time.

I happier news, my stem bearings and swing arm bushings are resting in the freezer, waiting to be installed once they're shrunk down a bit. I still need to track down a swing arm collar to complete the rear end. I have a new swing arm bolt w/dual zerg fittings to keep everything nice and greasy.